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“Road Vehicles — Endurance Braking Systems of Motor Vehicles and Towed Vehicles — Test Procedures”

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“Road Vehicles — Endurance Braking Systems of Motor Vehicles and Towed Vehicles — Test Procedures” Presentation to GRRF, 55th Session, Geneva Febr. 3rd, 2004 ISO CD 12161 Doc TC22/SC2 N 597 “Road vehicles — Endurance braking systems of motor vehicles and towed vehicles — Test procedures” by ISO TC22/SC2/WG6 SWG 6 „Endurance braking systems“ Dr. Reinhold Pittius (VOITH TURBO) Pittius 2004-02-03 page 1 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 1. Structure of ISO Working Group Subworking group SWG 6 „Endurance braking systems“ Chairman Dr. Reinhold Pittius • reporting to ISO 22/2/WG6 „Braking Systems“ Chairman Prof. v. Glasner • Active members of SWG 6: DaimlerChrysler TELMA IVECO VOITH TURBO MAN ZF • Status - Working Draft agreed by TC22 Æ Committee Draft (CD) - Distribution as ISO DIS in Dec. 2003 - Balloting until May 2004 Pittius 2004-02-03 page 2 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 Contents 1. Structure of ISO Working Group 2. The Target 3. Basic legal requirements 4. Basic understanding of equivalent energy 5. Specific properties of different types of retarders 6. Test methods 7. Conclusion Pittius 2004-02-03 page 3 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 2. The Target Standardization • of testing procedures • of vehicles - equipped with endurance braking systems - to be type approved • according to existing legal requirements ¾ Detailed description of ¾ different test methods such that ¾ results are • objectiv, • realistic and • compatible Pittius 2004-02-03 page 4 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 3. Basic legal requirements (1) ECE-R 13, Annexe 4 para. 1.6 Type II 6 km 30 km/h 6 % para 1.8 Type IIA service brakes 6 km must not be used ! 30 km/h 7 % Pittius 2004-02-03 page 5 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 3. Basic legal requirements (2) Pittius 2004-02-03 page 6 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 3. Basic legal requirements (3) Pittius 2004-02-03 page 7 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 3. Basic legal requirements (4) = Equivalent same in the energy ! average same time power ! Pittius 2004-02-03 page 8 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 4. Basic understanding (1) Key philosophy of ISO CD 12161 with regard to the standardization of performance tests of endurance braking systems = Equivalent same in the energy ! average same time power ! W = m*g*∆H 1) P = W / t t = L / v = m*g*L*tan α 1) rolling resistance to be considered! Pittius 2004-02-03 page 9 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 4. Basic understanding (2) Equivalent Energy in time ? Yes Æ Approval ! Downhill test - (preference IVECO) page 10 Towing test - (preference MAN) Test bench - (preference DC) Pittius 2004-02-03 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 5 Specific properties of different types of retarders (1) Engine brake vs secondary (hydrodynamic) retarder -1 Getriebe: ZF S6-90 nMot-min/max 1200 / 2000 min Rdyn 0,502 m Masse 18000 kg iHa 3,33 fr 1,0 % Bremsmoment [Nm] Verzögerung [%] 5.000 100 kW 200 kW 300 kW 400 kW 500 kW 600 kW 19,0 4.500 Comparison Exhaust Brake vs Secundary Retarder 17,0 • Torque vs speed 1. Gang 4.000 15,0 3.500 Average (engine = 1600 min-1) • Power vs speed Voith Retarder 133-2 (3750Nm) 13,0 3.000 • controllability 2. Gang 11,0 2.500 9,0 2.000 Type IIa 7,0 1.500 3. Gang● 1.000 4. Gang 5,0 5. Gang 500 3,0 6.Gang Source: Voith Analysis 0 1,0 0 102030405060708090100v [km/h] Pittius 2004-02-03 page 11 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 5 Specific properties of different types of retarders (2) Electromagnetic vs hydrodynamic retarder oil Thermal performance stator rotor Pittius 2004-02-03 page 12 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 5 Specific properties of different types of retarders (3) Service Brake Electromagnetic Retarder Hydrodynamic Retarder elimination elimination continus braking capability continus braking capability through through cooling cooling time limited time limited time limited system system capacitive radiation capacitive radiation capacitive radiation absorption via absorption via absorption via surface surface surface Pittius 2004-02-03 page 13 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 6.1 Test methods – Downhill test (1) Specific criterias: There is no real downhill track having exactly 7% and 6km length Perhaps the height difference is available, but not Only small tolerances on exactly the length (resp. CD 12161 equivalant energy and time ! the slope) • tolerances on slope variation Even if the height and the but lenght are correct, the • compensation on average slope slope may vary along the track. • compensation on height difference Pittius 2004-02-03 page 14 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 6.1 Test methods – Downhill test (2) Height profile of a realistic test track 850 Parkplatz Torfhaus bei km 11,3 (810 m über NN) 800 . Height [m] . 750 . Height Profile of . 700 Fed. Road B4 near . gemessen . Torfhaus . 650 . Akima-Fkt. 600 . LZA bei km 8,0 (620 m über NN) . 550 . 500 . 450 . 400 . Parkplatz Steinbruch bei km 4,0 (370 m über NN) 350 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10 10.5 11 Pittius 2004-02-03 11.5 12 Length [km] page 15 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 6.1 Test methods – Downhill test (3) Downhill test - procedure • „Qualifying“ of desired downhill track acc. to explained criterias • Calculation of compensation parameters such as speed, mass etc. Top m = const. • nearly no instrumentation necessary P = const. variable • performance of the downhill test run tan • measurement of the time needed • if less then required time Æ DONE Bottom variable l Pittius 2004-02-03 page 16 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 6.2 Test methods – Towing test (1) Specific criterias: The braking force may vary due to retarder charactaristic The speed of the combination may due to Only small tolerances on the variation or force CD 12161 equivalant energy and time ! If the the towed vehicle has not fully laden the rolling but • tolerances on force variation resistance must be • tolerance on speed variation considered at the evaluation of the test. • compensation of GVW and rolling resistance Pittius 2004-02-03 page 17 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 6.2 Test methods – Towing test (2) Towing test - procedure • „Qualifying“ of vehicles and test conditions • Compensation of rolling resistance and determination of requ. force • Instrumentation of vehicles necessary • performance of the towing test 12 min and data recording • postprocessing of test data Æ calculation of braking energy • if equal to equivalent energy Æ DONE Pittius 2004-02-03 page 18 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 6.3 Test methods –Dynamometer test bench (1) Specific criterias: The braking force may vary due to retarder charactaristic The speed of the test bench may due to the variation or force Only small tolerances on If the the measured vehicle is CD 12161 equivalant energy and time ! not fully laden the rolling resistance must be but • tolerances on force variation considered at the • tolerance on speed variation evaluation of the test. A cooling device must • compensation of GVW and simulate the air stream rolling resistance due to the vehicle speed Pittius 2004-02-03 page 19 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 6.3 Test methods –Dynamometer test bench (2) Simulation test - procedure • „Qualifying“ and instrumentation of the test bench • Compensation of rolling resistance and determination of requ. force • performance of the towing test 12 min and data recording • postprocessing of test data Æ calculation of braking energy • if equal to equivalent energy Æ DONE Pittius 2004-02-03 page 20 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 7 Specific test parameters for engine brakes (1) Speed tolerance 30 ± 5 km/h -1 Getriebe: ZF S6-90 n Mot-min/max 1200 / 2000 min Rdyn 0,502 m Masse 18000 kg iHa 3,33 fr 1,0 % Bremsmoment [Nm] Verzögerung [%] 5.000 100 kW 200 kW 300 kW 400 kW 500 kW 600 kW 19,0 4.500 Comparison Exhaust Brake vs Secundary Retarder 1. Gang 17,0 ¾ All primary retarders shall 4.000 15,0 3.500 Average (engine = 1600 min-1) Voith Retarder 133-2 (3750Nm) be treated same as engine 13,0 3.000 2. Gang 11,0 retarders 2.500 9,0 2.000 Type IIa 7,0 • because they operate 1.500 3. Gang● 1.000 4. Gang 5,0 5. Gang 500 3,0 via the gearbox as well 6.Gang Source: Voith Analysis 0 1,0 Pittius 2004-02-03 0 102030405060708090100pagev [km/h] 21 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 7 Specific test parameters for engine brakes (2) Deceleration test ≥ 0.6 m/s² ¾ The deceleration test is NOT covered by the ISO CD 12161 • because this test is not „in line“ with the general idea of the equivalent energy Pittius 2004-02-03 page 22 ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 6 Conclusion (1) • ISO CD 12161 • provides detailed definitions of three test procedures according to the principle of equivalent energy • the test procedures have been harmonized based on the principle of equivalent energy • allows adequate and individual decisions on the test procedure.
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